Dry wipe

ABSTRACT

A bulky fibrous fabric is provided, made by a process comprising obtaining an unbonded, consolidated batt of fibers wherein each fiber has a ribbon-shaped cross-section, and needling said batt to obtain the bulky fibrous fabric. The fabric has a surface area of at least 2 m 2 /g and a thickness/basis weight ratio of at least 0.005 mm/g/m 2  (7 mil/oz/yd 2 ) The fabric has utility particularly as a dry wipe for cleaning and dusting.

FIELD OF THE INVENTION

[0001] The invention relates to a needled fibrous batt made from fibershaving a ribbon-shaped cross-section.

BACKGROUND OF THE INVENTION

[0002] There exists a need for a material in the form of a dry wipe fordusting and cleaning which attracts and entraps dust and dirt particlesduring use more effectively than existing dry wipes and which may bemanufactured more economically than existing dry wipes.

[0003] Nonwoven dry wipes containing spunlaced layers of polyester weband scrim are commercially available. Examples of such dry wipes areSwiffer®, available from The Procter & Gamble Company, Cincinnati, Ohio,and Grab-It®), available from S. C. Johnson & Son, Inc., Racine, Wis.,which are generally made by needling round polyester staple fibers intoa scrim. These wipes are electrostatically charged to attract dirt anddust, and the three-dimensional structure of the webs used is open sothat dirt particles are trapped by the wipes. Another example of a drydust wipe is Scotch-Brite®, available from Minnesota Mining andManufacturing Company, St. Paul, Minn., made from spunlaced webs ofpolyester staple fibers having longitudinal grooves therein.

[0004] U.S. Pat. No. 5,290,628 (Lim et al.) discloses a process forhydraulically needling a web of staple fibers into an unbonded flashspun web made of continuous plexifilaments to form a spunlaced nonwovenfabric. The flash spun web may optionally be bonded to increase thelevel of permeability of the nonwoven fabric. Disclosed as end uses forthe nonwoven fabric are filtration applications, and bulky, downproofand featherproof barrier liners for garments, sleeping bags, pillows,comforters and the like.

[0005] U.S. Pat. No. 4,704,321 (Zafiroglu) discloses a nonwoven fabric,useful as a wipe-cloth, comprising a layer of nonbonded, polyethyleneplexifilamentary film-fibril strands, the layer being stitched throughwith thread that forms spaced apart rows of stitches extending along thelength of the fabric. Zafiroglu found that standard thermally bondedplexifilamentary sheets were not functional for wiping cloths becauseafter thermal bonding to generate structural integrity the dustretention was inadequate, and the non thermally bonded, coldconsolidated sheet lacked sufficient surface stability for a wipingcloth.

[0006] Japanese patent application Hei 4-196066, assigned to JapanVilene Co. Ltd., discloses a nonwoven fabric cleaning wipe havingsuperior dust attracting ability, and a process for making such a wipe.

SUMMARY OF THE INVENTION

[0007] The invention provides a bulky fibrous fabric comprising a battof fibers each fiber having a ribbon-shaped cross-section, the batthaving a surface area of at least 2 m²/g and a thickness/basis weightratio of at least 0.005 mm/g/m².

[0008] In another embodiment of the invention, a bulky fibrous fabric isprovided by a process comprising:

[0009] a) obtaining an unbonded, consolidated batt of fibers whereineach fiber has a ribbon-shaped cross-section; and

[0010] b) needling said batt to obtain the bulky fibrous fabric having asurface area of at least 2 m²/g and a thickness/basis weight ratio of atleast 0.005 mm/g/m².

DETAILED DESCRIPTION OF THE INVENTION

[0011] 30 The process by which the bulky fibrous fabric of the inventionis made will now be described in detail. A batt of fibers, eachindividual fiber having a ribbon-shaped cross-section, is obtained. By“ribbon-shaped” is meant that the average aspect ratio of the individualfiber cross-section is between 1.4 and 6.8. The batt of fibers may beobtained by a variety of known methods. One known method is fordifferent cross-sectional shaped melt-spun fibers, such as star-shapedfibers, to be spunlaced and subsequently broken into smallerribbon-shaped fibers.

[0012] Preferably, the batt consists of overlapping continuousplexifilamentary film-fibril strands, formed by flash-spinningtechniques generally described in U.S. Pat. No. 3,851,023 (Brethauer etal.), herein incorporated by reference. The film-fibrils are very thinribbon-like fibrous elements, which are generally less than 20 micronsthick. The cross-section of each fiber in a plexifilamentary strand isgenerally ribbon-shaped.

[0013] Preferably, the flash-spun batt is formed from polyolefinpolymer, and more preferably, high density polyethylene polymer. Thespin agent with which the polymer is mixed is preferably a blend ofpentane and cyclopentane. The spin agent may also be a refrigerant suchas Freon@, available from E. I. du Pont de Nemours and Company, Inc.,Wilmington, Del.

[0014] In order to achieve the desired bulkiness in the final product,the percentage of polymer in the polymer-spin agent mixture ispreferably between 15 and 25%, most preferably 17%. The temperature ofthe polymer and spin agent mixture just prior to being emitted throughthe spin orifice should be maintained at between 185 and 200 degrees C.,most preferably 190 degrees C.

[0015] As described in U.S. Pat. No. 3,851,023, the plexifilamentaryfilm-fibril strands are electrostatically charged in order to pin themto the moving belt on which they are collected as they are spun. Theelectrostatic charge imparted is high enough to overcome the vapor blastor high turbulence that may exist in the web forming chamber.

[0016] By “consolidated” is meant that the as-formed batt has beenlightly compressed by a nip roll so that it may be handled as a sheet.By “unbonded” is meant that the batt has not been further bonded bychemical or thermal means, such as by compaction by heated rolls orplates, so that the batt has not become a coherent sheet. In thepreferred embodiment in which the batt is obtained by flash spinning,the individual plexifilamentary webs which overlap one another to makeup the unbonded, consolidated batt are held together in such a way thatthe batt may be handled as a sheet but the individual webs may be easilypulled away from the surface of the batt.

[0017] The batt is needled in order to form the bulky fibrous fabric ofthe invention. The needling may take the form of hydroentangling, suchas described in U.S. Pat. No. 3,485,706. As stated in U.S. Pat. No.3,485,706, the hydroentangling is carried out by subjecting the batt tohigh pressure liquid streams of at least 200 psig while supported by anapertured member, such as perforated plate or woven wire screen. Thenumber of jets, jet type, jet pressure and apertured member can bevaried to achieve various fabric strength, surface stability andthickness.

[0018] Preferably, the needling is carried out by needlepunching in aneedle machine to obtain the fabric of the invention having a thicknessof at least 0.20 millimeters, a basis weight of between 37 and 78 g/m²,and a thickness/basis weight ratio of at least 0.005 mm/g/m² (7mil/oz/yd²). The needle density, or “punch density,” is between 60 and500/cm², preferably between 200 and 300/cm², on each side of the batt.The needle penetration is between 5 and 10 mm on each surface of thebatt, preferably about 5 mm. The needle pattern is random such that theneedle punches are approximately evenly spaced across both surfaces ofthe batt.

[0019] Since the bulky fibrous fabric of the invention is obtained bysimply needling an unbonded, consolidated batt of fibers, the bulkyfibrous fabric may be manufactured more economically than existing drydust wipes made by needling staple fibers into a scrim.

Test Methods

[0020] Basis Weight was determined by ASTM D-3776, which is herebyincorporated by reference, and is reported in g/m².

[0021] Tensile Strength was determined by ASTM D 5035-95, which ishereby incorporated by reference, with the following modifications. Inthe test a 2.54 cm by 20.32 cm (1 inch by 8 inch) sample was clamped atopposite ends of the sample. The clamps were attached 12.7 cm (5 inches)from each other on the sample. The sample was pulled steadily at a speedof 5.08 cm/min (2 inches/min) until the sample broke. The force at breakwas recorded in pounds/inch and converted to Newtons/cm as the breakingtensile strength.

[0022] Thickness was determined by ASTM D177-64, which is herebyincorporated by reference, and is reported in millimeters.

[0023] Grab Tensile Strength was determined by ASTM D 5034-95, which ishereby incorporated by reference, recorded in pounds/inch and convertedto Newtons/cm.

[0024] Elongation to Break of a sheet is a measure of the amount a sheetstretches prior to breaking in a strip tensile test. A 2.54 cm (1 inch)wide sample is mounted in the clamps, set 12.7 cm (5 inches) apart, of aconstant rate of extension tensile testing machine such as an Instrontable model tester. A continuously increasing load is applied to thesample at a crosshead speed of 5.08 cm/min (2 inches/min) until failure.The measurement is given in percentage of stretch prior to failure. Thetest generally follows ASTM D 5035-95.

[0025] Grab Elongation to Break was determined by ASTM D5034-95, whichis hereby incorporated by reference, and recorded in %.

[0026] Density was calculated from measured basis weight divided bymeasured thickness and is reported in gram/cm³.

[0027] Void Fraction was calculated as (1-calculated density/0.95)×100and is reported in %.

[0028] Wiping Performance Test is a measure of a material's cleaningperformance as a dust mop. For the test results reported herein, threetest environments were used, referred to as Home, Light Industrial andHeavy Industrial. The Home environment was the floor of an office areawhich was cleaned daily. The Light Industrial environment was a busyhallway in a manufacturing area which had more traffic than the Homeenvironment and was not cleaned daily. The Heavy Industrial environmenthad forklift truck traffic and was never cleaned. The materials to betested were cut into samples measuring approximately 5 inches by 11inches. Each sample was weighed and the weight recorded. Two samples tobe compared were secured to the bottom surface of a dry mop with a flat,smooth rubber bottom surface. The mopping surface of the mop wasapproximately 10 inches by 3 inches. The mop was pushed over a fiftyfoot section of the floor. The samples were then removed from the mopand folded in such a way that the dust collected by each sample was heldwithin that sample. Each sample was reweighed to determine the amount ofdust collected by that sample. The percent performance was determined bydividing the dust collected by the dust collected by the incumbent, orcomparison sample, and multiplying by 100%. This means that theincumbent will always have 100% performance, while the invention examplewill have a percent relative to the incumbent. Values less than 100%indicate inferior performance, while values greater than 100% indicatesuperior performance. Seven to ten sample pairs were run for eachenvironment and the result is the average.

[0029] Fiber Surface Stability Test is a measure of how cohesive asurface is when exposed to a destructive external force. For this test,the samples were exposed to standard Scotch transparent tape, availablefrom 3M, St. Paul, Minn. Four measurements were taken on one surface ofthe sample and four on the other. Eight (8) seven-inch pieces of tapewere cut and weighed, and the initial weight recorded. Each piece oftape was applied to the surface to be tested and rubbed evenly to insurecontact between the tape and the sample surface. The tape is then pulledaway from the sample, then reapplied and pulled away for a total of fivetimes for each piece of tape. Each piece of tape is weighed a secondtime and the final weight recorded. The final and initial weights foreach piece of tape were used to calculate the weight of the fibersremoved from the sample surface. An average was calculated for each sideof the sample. The more fiber lost by the surface of the sample, themore unstable the surface of the sample is. The results are reported ingrams.

[0030] Surface Area is calculated from the amount of nitrogen absorbedby a sample at liquid nitrogen temperatures by means of theBrunauer-Emmet-Teller equation and is given in m²/g. The nitrogenabsorption is determined using a Stohlein Surface Area Metermanufactured by Standard Instrumentation, Inc., Charleston, W. Va. Thetest method applied is found in the J. Am. Chem. Soc., V. 60 p. 309-319(1938).

EXAMPLES 1-13

[0031] Flash spun unbonded batts were obtained by flash spinning highdensity polyethylene at various concentrations in a blend of pentane andcyclopentane spin agent at various temperatures by a process asdescribed in Brethauer. The batts were lightly consolidated using a niproll. The spinning conditions (percent polymer in spin agent andspinning temperature) and properties measured for each of these battsare listed as Comparative Examples 1-6 in Table 1.

[0032] The batts were then needlepunched in a needle machine using a4500 needles per meter board on each of the top and bottom surfaces.Each batt was needled at a punch density of 60/cm² on each side and aneedle penetration of 10 mm on the top surface and 5 mm on the bottom. Arandom needle pattern was used. The output speed was 6-7 meters perminute. The properties of these needlepunched batts, or nonwovenfabrics, are listed as Examples 1-9 in Table 1. Examples 1-9 are thenonwoven fabrics resulting from needlepunching the batts of ComparativeExamples 1-6. Comparative Examples 1, 2, 4 and 6 provided the startingmaterial for Examples 1, 2, 5 and 9, respectively. Comparative Example 3provided the starting material for both Examples 3 and 4. ComparativeExample 5 provided the starting material for Examples 6, 7 and 8.

[0033] The properties of nonwoven fabrics Swiffer® (commerciallyavailable from The Procter and Gamble Company, Cincinnati, Ohio) andGrab It® (commercially available from S. C. Johnson & Son, Inc., Racine,Wis.) were measured and listed in Table 1 as Comparative Examples 7 and8.

[0034] The thickness/basis weight (BW) ratio is a measure of thebulkiness of the fabric. The higher the thickness/BW, the bulkier thefabric. The thickness/BW of the unbonded, unneedled batt (ComparativeExamples 1-6) ranges from 4.5 to 5.2 depending on the basis weight andspinning conditions. The thickness/BW of needlepunched fabric (Examples1-9) ranges from 7.2 to 7.9. The increase in thickness/BW of theneedlepunched fabric is attributed to fiber entanglement caused by theaction of the needles. This phenomenon is contrary to typicalneedlepunching of webs where the needles cause the web to consolidateand lower the thickness. This increased thickness/BW ratio, orbulkiness, is important for the wiping performance of the fabric of theinvention, since it provides greater capacity for the fabric to captureand store dust and dirt particles.

[0035] Slight increases in the mechanical properties of Examples 1-9 ascompared with Comparative Examples 1-6, specifically grab tensilestrength, grab elongation to break, tensile strength and elongation tobreak, are attributed to the fiber entanglements caused by theneedlepunching process. The mechanical properties are increased withincreasing basis weight. A 54 g/m² needlepunched fabric has a similarrange of mechanical properties as the current incumbent wipe products.

[0036] Table 2 illustrates the effects on surface stability and wipingperformance when the spinning conditions are held constant and theneedling density and penetration are varied. Examples 8 and 10-13 arebased on the starting batt material of Comparative Example 5, and eachis needlepunched at a different needle density and penetration (on theupper and lower sides), listed in Table 2. Surface area measurements arealso included in Table 2.

[0037] Surface area measurements were made on the existing dust wipematerials, Swiffer® and Grab-It® (Comparative Examples 7 and 8), and theresult was 0.0 m²/g, meaning less than 0.1 m²/g. TABLE 1 ComparisonComparison Comparison Comparison Comparison Comparison Example 1 2 3 4 56 1 2 Spun condition (% polymer, 17/190 17/197 17/200 20/200 17/19017/190 17/190 17/197 degrees C) Basis Weight (g/m²) 41 41 54 51 54 78 3741 Thickness (mm) 0.159 0.155 0.203 0.198 0.203 0.264 0.221 0.236Thickness/Basis 3.90E − 06 3.80E − 06 3.80E − 06 3.90E − 06 3.80E − 063.40E − 06 6.00E − 06 5.80E − 06 Weight (m³/g) Density (g/cm³) 0.2570.263 0.267 0.257 0.267 0.295 0.169 0.172 Void Fraction (%) 73 72.3 71.972.9 71.9 68.9 82.2 81.9 Grab Tenacity MD/CD (N/cm) 5./10 5./9 12./469./47 19/28 24/46 10./12 10./16 Grab Elongation MD/CD (%) 44/64 43/5750/34 40/51 41/53 45/39 43/45 Tensile MD/CD (N/cm) 1.9/2.3 1.7/1.72.6/8.9 2.6/8.8 3.5/4.5 6.6/6.6 1.9/3.1 2.6/3.3 Elongation MD/CD (%)4./15 6./13 15/23 15/23 9./13 9.4/11.4 26/27 29/28 Fiber SurfaceStability: Belt side (g) 0.0975 0.0614 0.0461 0.295 0.554 0.149 0.04960.0505 Top side (g) 0.302 0.143 0.0667 0.0646 0.156 0.276 0.0657 0.0708Wiping Performance (%): Home environment 81 110 76 90 105 170 LightIndustrial 81 100 87 82 90 100 130 Heavy Industrial 76 100 85 100 85 7580 Comparison Comparison Example 3 4 5 6 7 8 9 7 8 Spun condition (%17/200 17/200 20/200 17/190 17/190 17/190 17/190 polymer, degrees C)Basis Weight (g/m²) 49 51 51 56 48 51 78 64 58 Thickness (mm) 0.2870.274 0.292 0.307 0.251 0.3 0.414 0.297 0.305 Thickness/Basis 5.90E − 065.40E − 06 5.70E − 06 5.50E − 06 5.20E − 06 5.90E − 06 5.30E − 06 4.60E− 06 5.30E − 06 Weight (m³/g) Density (g/cm³) 0.171 0.186 0.174 0.1830.192 0.17 0.189 Void Fraction (%) 82 80.4 81.7 80.7 79.8 82.1 80.1 GrabTenacity 18/24 18/21 30/44 30/35 44/53 16/9 28/9 MD/CD (N/cm) GrabElongation 82/55 53/30 53/34 47/43 49/36 112/78 56/71 MD/CD (%) TensileMD/CD 4.7/7.9 3.8/8.4 7./12 7./8.8 9./16 7./2.8 17/3 (N/cm) Elongation41/36 37/33 39/41 34/35 34/29 56/29 50/44 MD/CD (%) Fiber SurfaceStability: Belt side (g) 0.0061 0.0143 0.0148 0.0385 0.0405 0.00480.0122 0.0244 0.00754 Top side (g) 0.0344 0.0724 0.0236 0.0208 0.05130.0129 0.0045 0.0667 0.0043 Wiping Performance (%): Home environment 110130 117/150 108 100/130 100 Light Industrial 122 117 110/120 83 107/86100 Heavy Industrial 107 107 100/90 100 107/80 100

[0038] TABLE 2 Example Comparison 5 8 10 11 12 13 Spun conditions (%polymer/degrees C) 17/190 17/190 17/190 17/190 17/190 17/190 Needle(density/penetration upper/lower): Density (needles/cm²) 60 100 100 150225 Penetration (upper/lower) (mm) 10./5 10.0/5 5.0/5 5.0/5 5.0/5 BasisWeight (g/m²) 54 51 51 51 51 51 Thickness (mm) 0.203 0.3 0.31 0.2970.312 0.368 Thickness/BW (m³/g) 3.80E − 06 5.90E − 06 6.10E − 06 5.80E −06 6.10E − 06 7.20E − 06 Density (g/cm³) 0.267 0.17 0.164 0.172 0.1630.138 Void Fraction (%) 71.9 82.1 82.7 81.9 82.8 85.5 Grab TenacityMD/CD (N/cm) 19/28 30/35 23/28 30/31 23/22 30/31 Grab Elongation MD/CD(%) 40/51 47/43 50/44 52/47 47/41.6 52/43.6 Tensile MD/CD (N/cm) 3.5/4.57/8.8 7/7.9 7.7/8.8 7.5/6.6 6.6/8.9 Elongation MD/CD (%) 9./13 34/3532/35 29/32 27/33 30.2/34 Fiber Surface Stability: Belt side (g) 0.5540.0048 0.0194 0.011 0.079 0.016 Top side (g) 0.156 0.0129 0.0108 0.0170.023 0.016 Wiping vs. Swiffer: Home environment 76 109/130 93 138 110150 Light Industrial 82 122/86 126 114 114 118 Heavy Industrial 10098/80 93 100 106 107 Surface Area (m²/g) 15.3 11.8 9.5 10.8 8.4 9.7

EXAMPLES 14-17

[0039] Flash spun unbonded batts were obtained by flash spinning highdensity polyethylene at various concentrations in a blend of pentane andcyclopentane spin agent at various temperatures by a process asdescribed in Brethauer. The batts were lightly consolidated using a niproll. The spinning conditions (percent polymer in spin agent andspinning temperature) and properties measured for each of these battsare listed as Comparative Examples 1-6 in Table 1.

[0040] The batts were then hydroentangled using high pressure water oneach of the top and bottom surfaces. The number of jets, jet type, jetpressure and apertured member were varied to achieve various fabricstrength, fiber surface stability and thickness. The properties of thesehydroentangled batts, or nonwoven fabrics, are listed as Examples 14-17in Table 3. In each case, the batt was supported on a first aperturedmember and hydroentangled by making several passes under high pressurewater jets with the line running at 50 yards per minute. The batt wasthen turned over, placed on a second apertured member and againhydroentangled by making several passes under high pressure water jetswith the line running at 50 yards per minute. TABLE 3 Example 14 15 1617 Spun condition (% polymer/degrees C) 17/200 17/200 17/200 17/200Water jet pressure Low Pressure High Pressure Low Pressure Basis Weight(g/m²) 47 58 58 58 Thickness (mm) 0.292 0.318 0.356 0.356 Thickness/BW(m³/g) 6.20E − 06 5.50E − 06 6.10E − 06 6.10E − 06 Density (g/cm³) VoidFraction (%) Grab Tenacity MD/CD (N/cm) 42 58 47 42 Grab ElongationMD/CD (%) 46 34 36 44 Tensile MD/CD (N/cm) 25.4 12.2 19.2 14 ElongationMD/CD (%) 24 40 37 37 Fiber Surface Stability: Belt side (g) 0.018 0.0060.003 Top side (g) 0.013 0.01 0.003 Wiping vs. Swiffer: Home environment80 130 110 Light Industrial Heavy Industrial 95 96 91 Surface Area(m²/g) 8.6 8 6.3 7.1

EXAMPLE 14

[0041] During the first pass of hydroentangling, the batt was supportedon a first apertured member of a 75 mesh woven wire. Four jets wereused. During the second pass of hydroentangling, the batt was supportedon a second apertured member of a perforated plate having a cloverpattern with a 20 mesh sub screen. Three jets were used. The jet holediameters, number of holes per inch per jet, and the jet operatingpressures are listed below in Table 4. TABLE 4 Hole diameter PressureJet (mils) Holes per inch (psi) First Pass 1 4 80 500 2 5 40 1000 3 5 401500 4 5 40 1500 Second Pass 1 4 80 300 2 5 40 500 3 5 40 1000

EXAMPLE 15

[0042] During the first pass of hydroentangling, the batt was supportedon a first apertured member of a 75 mesh woven wire. Four jets wereused. During the second pass of hydroentangling, the batt was supportedon a second apertured member of an 8 mesh woven wire. Four jets wereused. The jet parameters are listed in Table 5. TABLE 5 Hole diameterPressure Jet (mils) Holes per inch (psi) First Pass 1 4 80 500 2 5 401000 3 5 40 1500 4 5 40 1500 Second Pass 1 4 80 500 2 5 40 800 3 5 401000 4 5 40 1000

EXAMPLE 16

[0043] During the first pass of hydroentangling, the batt was supportedon a first apertured member of a 75 mesh woven wire. Four jets wereused. During the second pass of hydroentangling, the batt was supportedon a second apertured member of an 13 mesh woven wire. Eight jets wereused. The jet parameters are listed in Table 6. TABLE 6 Hole diameterPressure Jet (mils) Holes per inch (psi) First Pass 1 4 80 500 2 5 401000 3 5 40 1500 4 5 40 1500 Second Pass 1 4 80 300 2 4 80 500 3 5 40800 4 5 40 1000 5 5 40 1200 6 5 40 1500 7 5 40 1700 8 5 40 1800

EXAMPLE 17

[0044] During the first pass of hydroentangling, the batt was supportedon a first apertured member of a 75 mesh woven wire. Eight jets wereused. During the second pass of hydroentangling, the batt was supportedon a second apertured member of an 8 mesh woven wire. Eight jets wereused. The jet parameters are listed in Table 7. TABLE 7 Hole diameterPressure Jet (mils) Holes per inch (psi) First Pass 1 4 80 300 2 5 40500 3 5 40 800 4 5 40 1000 5 5 40 1200 6 5 40 1500 7 5 40 1800 8 5 401800 Second Pass 1 4 80 300 2 4 80 500 3 5 40 800 4 5 40 1000 5 5 401200 6 5 40 1500 7 5 40 1700 8 5 40 1800

What is claimed is:
 1. A bulky fibrous fabric comprising a batt offibers each fiber having a ribbon-shaped cross-section, the batt havinga surface area of at least 2 m2/g and a thickness/basis weight ratio ofat least 0.005 mm/g/m² (7 mil/oz/yd²).
 2. A bulky fibrous fabric made bya process comprising: a) obtaining an unbonded, consolidated batt offibers wherein each fiber has a ribbon-shaped cross-section; and b)needling said batt to obtain the bulky fibrous fabric having a surfacearea of at least 2 m²/g and a thickness/basis weight ratio of at least0.005 mm/g/m² (7 mil/oz/yd²).
 3. The bulky fibrous fabric of claim 2wherein the batt is made from flash-spun plexifilamentary film-fibrilweb.
 4. The bulky fibrous fabric of claim 2 or claim 3 wherein theneedling is performed by hydroentangling.
 5. The bulky fibrous fabric ofclaim 2 or claim 3 wherein the needling is performed by needlepunching.6. The bulky fibrous fabric of claim 1 wherein the bulky fibrous fabricis a nonwoven fabric and the fibers are polyolefin.
 7. The bulky fibrousfabric of claim 1 wherein the bulky fibrous fabric is a nonwoven fabricand the fibers are polyethylene.
 8. The bulky fibrous fabric of claim 6wherein the surface area is between 2 and 30 m²/g and thethickness/basis weight ratio is between 0.005 and 0.0075 mm/g/m².
 9. Abulky nonwoven fabric made by a process comprising: a) obtaining anunbonded, consolidated flash-spun batt; b) needlepunching saidflash-spun batt to obtain the bulky nonwoven fabric having a surfacearea of at least 2 m²/g, a thickness/basis weight ratio of at least0.005 mm/g/m², a thickness of at least 0.20 mm and a basis weight ofbetween 37 and 78 g/m².
 10. A dry wipe useful for cleaning and dustingmade from the bulky nonwoven fabric according to any of the precedingclaims.